Apparatus for producing center-filled confectionery and method

ABSTRACT

The present disclosure provides an apparatus and method for the continuous production of center-filled confectionery products. The apparatus may include an extruder for forming a continuous extrudate having a plurality of adjoined center-filled confectionery ropes. The apparatus may also include a forming device for forming individual confectionery pieces, and sealed center-filled confectionery pieces in particular. The apparatus provides improved coordination and control of extrudate formation and extrudate feed into the forming device. The apparatus and method of the present disclosure increases product output and reduces the amount of unacceptable product.

PRIORITY CLAIM

This application claims priority to U.S. patent application Ser. No.60/733,517 filed on Nov. 4, 2005 and U.S. patent application Ser. No.60/821,373 filed on Aug. 3, 2006, the entire content of each applicationincorporated herein.

BACKGROUND

Liquid or center-filled gum and other center-filled confectioneryproducts enjoy widespread popular appeal. These products typicallyexhibit a soft, chewy or pliable outer portion that surrounds a flavoredliquid or syrup center portion. The filled candy is often coated with ahard or a soft candy shell.

A problem encountered in the large scale production of such candies isthe inability to adequately control and coordinate the flow rate of thecenter fill material and/or the confectionery extrudate with theindividual piece forming process. Poor control and coordination of theseprocess parameters results in improperly sealed center fillconfectionery pieces. Improperly sealed pieces are particularlytroublesome as unsealed confectionery pieces leak a sticky, viscousfluid onto acceptable product pieces and/or production equipment. Thus,leaked fill material deleteriously impacts otherwise acceptableconfectionery pieces, contributes to material waste, and causesequipment stoppage. Moreover, conventional center fill productionsystems based on single rope extrusions are inherently limited inproduct output.

A need exists for an apparatus and method for controlling andcoordinating the extrusion process and the piece forming process,particularly in large scale production systems for center-filledconfectioneries. A need further exists for a production system thatovercomes the limitations of single rope extrusion systems.

SUMMARY

The present disclosure sets forth apparatuses and methods for thecontinuous production of center-filled confectionery products. Theapparatuses and methods set forth herein may increase product outputwhile providing improved control of process parameters such asextrusion, center fill extrusion, and/or coordination between extrudateformation and the formation of final individual pieces. Theseimprovements reduce the amount of unacceptable product and reduce systemand equipment downtime. The present disclosure also sets forth amultiple rope extrusion system that overcomes the output limitations ofsingle rope extrusion.

In an embodiment, an apparatus for producing a center-filledconfectionery product is provided. The apparatus includes an extruderfor forming a continuous extrudate, the extrudate having a plurality ofcenter-filled confectionery ropes and a forming device. The formingdevice includes first and second forming members that may be positionedon opposing sides of the extrudate. The forming members are constructedand arranged so as to cooperatively engage the extrudate to form asealed center-filled confectionery component.

In an embodiment, the extrudate may be an integral extrudate whereby theplurality of center-filled confectionery ropes are adjoined or connectedto each other to form a single uniform extrudate. Similarly, the sealedcenter-filled confectionery component may include a web of adjoinedsealed center-filled confectionery pieces. In an embodiment, theapparatus may include a separating device for separating the web into aplurality of discrete or separate sealed center-filled individualconfectionery pieces.

In an embodiment, the extrudate may further include a fill material thatis encased or otherwise surrounded in an outer confectionery material.In a further embodiment, the fill material may be a liquid and the outerconfectionery material may be a chewing gum. In an embodiment, eachsealed center-filled individual confectionery piece may include aperipheral flange that extends around an outer perimeter of theconfectionery piece. In an embodiment, the peripheral flange may includeonly the outer confectionery material and be substantially free of thefill material. In a further embodiment, the fill material may be cooledprior to extrudate formation in order to cool the extrudate from theinside. The fill material may have a temperature of from about 1° C. toabout 10° C.

In an embodiment, the apparatus may include a transport device forreceiving the continuous extrudate. The transport device may be used todeliver the extrudate to the forming device.

In an embodiment, at least one forming member may include an orifice foran air jet. The air jet may be used to discharge or eject thecenter-filled confectionery component from the forming member. Theforming members may be cooled to assist in removal of the finishedproduct therefrom. In an embodiment, at least one forming member mayhave a temperature from about 0° C. to about 20° C.

In an embodiment, the first forming member may be disposed on an outersurface of a first rotating drum and the second forming member may bedisposed on an outer surface of a second rotating drum. The first andsecond rotating drums may oppose each other and rotate to cooperativelyengage or mate the first forming member with the second forming memberthereby forming the separate center-filled confectionery pieces.

In an embodiment, the apparatus may include a coating device for coatingthe sealed center-filled confectionery component with a coatingmaterial. The coating may be a hard shell or a soft shell coating. Thecoating may be applied to the web of adjoined sealed confectionerypieces, or to each sealed center-filled individual confectionery piece.

In an embodiment, a method for producing a center-filled confectioneryproduct is provided. The method includes extruding an extrudate having aplurality of adjoined center-filled confectionery ropes, and forming theextrudate into a sealed center-filled confectionery component with aforming device. The method may further include passing the extrudatebetween a first forming member and a second forming member andcooperatively engaging, mating, or registering the forming members toform the sealed confectionery component. In an embodiment, the extrudingmay occur at a rate from about 2 m/min to about 20 m/min.

In an embodiment, the forming may include crimping and subsequentlycutting the extrudate. The method may include cooling the formingmembers to a temperature from about 0° C. to about 20° C. to assist inproduct discharge from the forming device.

In an embodiment, the sealed center-filled confectionery component maybe a web of adjoined sealed center-filled confectionery pieces and themethod may include separating the web into a plurality of discretecenter-filled individual confectionery products.

In an embodiment, the method may include filling each of the pluralityof confectionery ropes with a fill material. The fill material may becooled prior to the filling step to assist in cooling the extrudate.

In an embodiment, formation of the sealed center-filled confectionerycomponent may be coordinated with the filling of the confectionery ropeswith fill material. For example, the fill material may be intermittentlypumped into each confectionery rope during either the crimping and/orcutting step of product formation. This coordination may prevent abackflow of fill material into the conduits during the cutting.

In an embodiment, the method may include coating the sealedcenter-filled confectionery component with a coating material. Thecoating may be applied to the center-filled confectionery component, theweb of adjoined sealed confectionery pieces and/or each sealedcenter-filled individual confectionery piece.

In an embodiment, an apparatus for producing a center-filled extrudateis provided. The apparatus includes a manifold having a passageway. Aplurality of annular conduits extend through the passageway, with eachconduit having a discharge end. The apparatus includes an exit porthaving an orifice in fluid communication with the passageway and theconduit ends may be disposed in a spaced apart manner within theorifice.

In an embodiment, the conduit discharge ends may be disposed in a lineararrangement in the orifice. The orifice may further include a pluralityof wide portions corresponding to the plurality of annular conduits. Theorifice may also include a plurality of narrow portions separating thewide portions. In a further embodiment, the apparatus may include fromabout 2 to about 20 annular conduits.

The passageway may be adapted to receive a fluid confectionery and theannular conduits may be adapted to receive a flowable fill material. Thefluid confectionery may surround each conduit discharge end to form anextrudate having a plurality of center-filled confectionery ropes uponexit from the orifice. The number of ropes may correspond to the numberof conduits. Each confectionery rope may include an outer portion of thefluid confectionery and an inner portion of the fill material. Thediameter of the ropes may be substantially similar in length.

In an embodiment, the extrudate may include a strand portion of thefluid confectionery. The strand portion may be disposed between adjacentconfectionery ropes with the strand portion adjoining adjacentcenter-filled confectionery ropes.

In an embodiment, the manifold passageway may include a bend. Theapparatus may also include a flow regulator in fluid communication withan inlet end of each conduit for dispensing fill material into eachconfectionery rope. In an embodiment, the flow regulator may be used tointermittently pump the fill material through the plurality of conduitsand into the ropes. In yet a further embodiment, the fill material maybe cooled to a temperature from about 1° C. to about 15° C. to assistcooling the extrudate.

In an embodiment, a method for producing a center-filled extrudate isprovided. The method includes extruding a plurality of adjoined fluidconfectionery ropes and coextruding a fill material into eachconfectionery rope. This forms an extrudate having a plurality ofadjoined center-filled confectionery ropes. The confectionery ropes maybe disposed in a substantially linear arrangement as a result of fillmaterial coextruded from a plurality of spaced apart linearly disposedconduits. In an embodiment, the extruding and the coextruding may occursimultaneously or substantially simultaneously. The extruding and thecoextruding may also occur at a common exit port.

In an embodiment, the extruding may include forming with the fluidconfectionery an annular confectionery rope. The center fill materialmay be concentrically coextruded within the fluid confectionery ropes.In a further embodiment, the method may include forming theconfectionery ropes from a single flow of a fluid confectionerymaterial. The extrusion flow rate may be about 2 m/min to about 20 m/minfor the fluid confectionery material and/or the fill material.

In an embodiment, the method may include cooling the center fillmaterial to a temperature from about 1° C. to about 15° C. The flow rateof the fill material may be regulated upon introduction into theconfectionery ropes. In an embodiment, the fill material may beintermittently coextruded into the confectionery ropes.

Additional features and advantages are described herein, and will beapparent from, the following Detailed Description and the Figures.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view of an apparatus for producing acenter-filled confectionery in accordance with an embodiment of thepresent disclosure.

FIG. 2 is a perspective view of an apparatus for producing acenter-filled extrudate in accordance with an embodiment of the presentdisclosure.

FIG. 3 is a side elevation view of the apparatus of FIG. 2.

FIG. 4 is a front elevation view of the apparatus of FIG. 2.

FIG. 5 is an enlarged view of area 5 of FIG. 4.

FIG. 6 is a perspective view of an extrudate in accordance with anembodiment of the present disclosure.

FIG. 7 is a perspective view of a forming device in accordance with anembodiment of the present disclosure.

FIG. 9 is a perspective view of a center-filled confectionery piece inaccordance with an embodiment of the present disclosure.

FIG. 10 is a sectional view taken along line 10-10 of FIG. 9.

DETAILED DESCRIPTION

Referring to the Figures generally, where like reference numerals denotelike structure and elements, and in particular to FIGS. 1-3, anapparatus 10 for producing a center-filled confectionery is shown.Apparatus 10 includes an extruder 12, and a forming device 60.

Extruder 12 includes a manifold 14 that defines a passageway 16 havingan inlet 18 and an outlet 20. A plurality of annular conduits 22 mayextend through a portion of passageway 14. Although FIGS. 1, 2 and 4show 10 conduits extending through the passageway, it is understood thatapparatus 10 may include from about 2 conduits to about 10 conduits, orabout 20 conduits, or about 30 or more conduits, or any number ofconduits therebetween. In an embodiment, conduits 22 are substantiallyparallel to each other and may be disposed in a spaced apart lineararrangement as shown in FIG. 2.

Extruder 12 also includes an exit port 24 having an orifice 26. Exitport 24 may be secured to manifold 14 to provide fluid communicationbetween passageway outlet 20 and orifice 26. Each conduit has an inletend 28 and a discharge end 30. As conduits 22 may be arranged in aspaced apart manner, so too may discharge ends 30 be arranged in aspaced apart manner in orifice 26. Orifice 26 has a width A (FIG. 4)with sufficient length to accommodate spaced apart discharge ends 30. Inan embodiment discharge ends 30 are disposed in a spaced apart lineararrangement in orifice 26 as best seen in FIG. 4.

Turning to FIGS. 4 and 5, orifice 26 includes an outer edge 27 having awavy contour to give orifice 26 a shape that resembles a string ofbeads. Outer edge 27 defines a plurality of spaced apart wide portions32 with narrow portions 34 disposed therebetween. Wide portions 32correspond to the areas of orifice 26 in which conduit discharge ends 30are disposed. Consequently, wide portions 32 each have an extent ordiameter B (as seen in FIG. 5) that traverses discharge end 30 and alsotraverses a portion of orifice 26. Discharge ends 30 may be consideredto be substantially concentrically disposed within respective wideportions 32 so that wide portions 32 substantially surround respectivedischarge ends 30. In an embodiment, diameter B may have a length fromabout 1.0 mm to about 10 mm, or about 2 mm to about 8 mm, or about 3 mmto about 5 mm.

Orifice 26 also includes narrow portions 34, the narrow portionsdisposed between wide portions 32. In other words, narrow portions 34connect or otherwise adjoin adjacent wide portions 32 thereby forming asingle unitary orifice 26. Each narrow portion 34 has a distanceinterval C that extends between opposing edges 27 of the orifice. As canbe seen in FIG. 5, distance interval C does not traverse a conduitdischarge end. In an embodiment, extent B may be greater in length thandistance interval C. In a further embodiment, distance interval C mayhave a length from about 0.3 mm to about 1.5 mm, or about 0.5 mm toabout 1.0 mm.

In an embodiment, passageway 16 may be adapted to receive a fluidconfectionery 36 from a source (not shown) of confectionery materialsuch as a mixer or a hopper for example, as is commonly known in theart. The confectionery material may be any hard candy, soft candy,chewing gum, or other confectionery substance, or compound that has afluid phase or may take a fluid or a pliable form. In other words, theconfectionery material may be heated or melted, form a syrup, or bedissolved in a liquid to become flowable or fluid as is commonly knownin the art. The skilled artisan will appreciate that the moisturecontent (and concomitant viscosity) of the confectionery material mayvary greatly. The moisture content of the flowable phase of theconfectionery substrate may typically be in the range of about 0.5% toabout 20% by weight of the confectionery material. The fluidconfectionery material may be subsequently cooled or solidified at roomtemperature to form a solid or semi-solid confectionery. Nonlimitingexamples of suitable confectionery materials that are fluid or mayplaced into a fluid or pliable state include pastes, gels, syrups,liquids or solids for making hard candies, soft candies, lollipops,fondants, toffees, taffies, jellies (or gel candy), chewing gums,chocolates, gelatins and nougats. The fluid confectionery material mayinclude sugar or may be sugar-free. Coloring may be added to the fluidconfectionery material as desired. The confectionery material may alsoinclude a pharmaceutical product, an active ingredient, or a medicament.In an embodiment, fluid confectionery 36 may be a chewing gum. Althoughthe present disclosure is directed to confectionery materials, apparatus10 may be used to form other extrudable center-filled items such asother extrudable foods (i.e., starches, pastas) as well as center-filledpolymeric materials and products.

Conduit inlet ends 28 may be adapted to receive a fill material 38 froma fill source (not shown). Fill material 38 may be a flowable solidmaterial (i.e., a granular or powder material), a fluid confectionerymaterial, a liquid, a gel, a paste and combinations thereof. Similar tofluid confectionery 36, fill material 38 may be any hard candy, softcandy, chewing gum, or other confectionery substance, or compound thathas a fluid phase, may take a fluid form, or may be flowable. Fillmaterial 36 may include a pharmaceutical product, an active ingredient,or a medicament. Indeed, fluid confectionery 36 and fill material 38 maybe the same or different material. Fill material 38 may be heated,melted, dissolved, form a syrup, or become flowable or fluid as iscommonly known in the art. Consequently, fill material 38 may be aliquid, a semi-liquid, a syrup, a gel, a paste, a semi-solid or aflowable solid such as a granular solid or a confectionery in powderform at ambient conditions. In an embodiment, fill material 38 may be aliquid with a viscosity that may be adjusted as desired. The liquid maybe further sweetened, flavored, and/or colored as desired. In a furtherembodiment, fill material 38 may be a thixotropic fluid—i.e., a fluid orgel that becomes a fluid when agitated, stirred or shaken, and returnsto a semisolid state upon standing. One of ordinary skill in the artwould understand that the viscosity of a thixotropic fluid lowers thelonger the fluid/gel undergoes shear, with viscosity increasing when thefluid/gel is at rest to return the fluid/gel to a stable solid orsemisolid state at rest.

Extruder 12 includes a drive mechanism (not shown) as is commonly knownin the art to drive, force, or otherwise push fluid confectionery 36into passageway inlet 18 as shown by arrow D of FIG. 3. Fluidconfectionery 36 proceeds through passageway 16, through passagewayoutlet 20 and through orifice 26. At orifice 26, fluid confectionery 36fills the entire area of the orifice, filling orifice wide and narrowportions 32, 34. In so doing, fluid confectionery 36 surrounds orotherwise encases conduit discharge ends 30 at orifice 26.

In an embodiment, passageway 16 may include a bend 40. Bend 40 changesthe flow direction of confectionery 36 through manifold 14 as indicatedby curved arrow E of FIG. 3. Bend 40 may alter the confectionery flowangle from about 1° to about 90°. In an embodiment, bend 40 may have anangle of about 90° as shown in FIG. 3.

Extruder 12 may also include a flow regulator 42 to control the flow offill material 38 from the fill material source into and through conduits22 as shown by arrow F in FIG. 3. Each conduit 22 may have a dedicatedflow regulator. Alternatively, a single flow regulator may control theflow of fill material 38 into all conduits 22. Fill material 38continues through conduits 22 and is discharged from discharge ends 30at orifice 26. Confectionery 36, surrounding each discharge end 30 atorifice 26, subsequently surrounds or otherwise encases the flow of eachrespective fill material 38 upon exit from orifice 26. Extruder 12thereby forms a continuous extrudate 44 that includes a plurality ofcenter-filled confectionery ropes 46, the number of ropes correspondingto the number of conduits 22. Each rope 46 includes an inner portion 48of fill material 38 and an outer portion 50 of the fluid confectionery36, the outer portion 50 surrounding or wholly encasing inner portion 48of fill material as shown in FIG. 6. Extrudate 44 flows from extruder 12in the direction of arrow G as shown in FIGS. 1 and 3. FIG. 6 showsstrand portions 52, corresponding to fluid confectionery 36 extrudedfrom narrow portions 34. Strand portions 52 extend between adjacentropes 46 adjoining or otherwise attaching ropes 46 to each other.Consequently, extrudate 44 may be considered an integral extrudate.

In an embodiment, conduits 22 may be removed from manifold 14. In thisembodiment, the extrudate may be a plurality of single-phaseconfectionery ropes adhered to each other by way of the strand portions.In other words, removal of conduits 22 from manifold 14 eliminates thecenter-fill portion of the extrudate resulting in a single phase,multi-rope extrudate. The single phase multi-rope extrudate may befurther processed and/or formed and/or coated in any manner as describedherein for the extrudate 44. The single phase multi-rope extrudate maybe any confectionery material described herein. In an embodiment, thesingle phase multi-rope extrudate may be a chewing gum. Apparatus 10 mayadvantageously provide a high volume, efficient production system forthe production of single phase confectionery products.

Continuous extrudate 44 may be received by a transport device 54, suchas a conveyor, for example. In an embodiment, transport device 54 may bea belt cooler that receives and transports extrudate 44 away fromextruder 12 and simultaneously cools the extrudate. In an embodiment,apparatus 10 may include sizing rollers 56 to reduce the diameter ofone, some, or all of confectionery ropes 46 as is commonly known in theart.

In an embodiment, transport device 54 transports extrudate 44 to aforming device. The forming device may be any forming device as iscommonly known in the art. Non-limiting examples of suitable formingdevices include opposing first and second rotating drum mechanisms,rotating drum and continuous chain mechanisms, and rotating drummechanisms having die and cutter rings with mating die members. Theextrudate 44 may enter the forming device as a plurality of adjoinedfilled, or center-filled, confectionery ropes (such as the extrudateshown in FIG. 1, for example). Alternatively, extrudate 44 may bedivided or otherwise separated into a plurality of individual or singlecenter-filled confectionery ropes prior to entering the forming device.This may be accomplished by placing one or more dividing devices in theflow of extrudate 44. The dividing device may have a sharp point or tipthat opposes the oncoming strand portions 52 to split, separate, divide,or cut extrudate 44 along the strand portions and into a plurality ofindividual ropes upstream of the forming device. Each individual ropemay then be directed to the same forming device or different formingdevices as is commonly known in the art.

In an embodiment, transport device 54 transports extrudate 44 to formingdevice 60 as shown in FIGS. 1 and 7. Forming device 60 may include afirst forming member 62 and a second forming member 64, forming members62, 64 disposed on opposing of extrudate 44. Each forming member 62, 64may be constructed or otherwise shaped to form half of finished product,forming members 62, 64 mating to form a full or complete confectionerypiece or web, when forming members 62, 64 are placed in registrationwith each other. Forming members 62, 64 may cooperatively engageextrudate 44 in order to crimp and cut extrudate 44, thereby forming asealed center-filled confectionery component 66.

In an embodiment, forming device 60 may be a pair of opposing rotatingdrums 68, 70 disposed on opposing sides of extrudate 44, drums 68, 70contra-rotating to form sealed center-filled component 66. In thisembodiment, first forming member 62 may be disposed on a circumferentialsurface of rotating drum 68. First forming member 62 may extend alongsubstantially the entire length of drum 68 in order to accommodate theentire width of extrudate 44. In a further embodiment, rotating drum 68may include a plurality of first forming members 62, the forming membersextending around substantially the entire circumferential surface ofdrum 68 as shown in FIGS. 1 and 7.

Similarly, second forming member 64 may be disposed on a circumferentialsurface of rotating drum 70. In an embodiment, a plurality of formingmembers 64 may cover substantially the entire circumferential,peripheral, or outer surface of rotating drum 70. Rotating drums 68, 70may rotate in contrary motion as indicated by arrows H and I, to bringforming members 62, 64 into cooperative registration with each other.First and second forming members 62, 64 are configured to matingly formthe shape of the final confectionery product when brought intocooperative engagement with each other. Rotation of drums 68, 70 bringsforming members 62, 64 into contact with extrudate 44, whereby continueddrum rotation crimps or otherwise squeezes opposing sides of outerportion 50 into contact with each other to form a seal around innerportion 48 (i.e., fill material 38) of each confectionery rope 46.Further rotation of drums 68, 70 brings forming members 62, 64 intofurther cooperation with each other to perforate or otherwise cutextrudate 44 and form sealed center-filled confectionery component 66.The shape of each forming member 62, 64 may be varied as desired toyield a confectionery component having an spheroidal, polygonal,elliptical shape as desired. Although FIG. 7 shows extrudate 44, aplurality of center-filled extrudate ropes, passing through formingdevice 60, it is understood that forming device 60 may be used to form asealed confectionery piece from a single center-filled rope extrudate.

In an embodiment, sealed center-filled confectionery component 66 mayinclude a web 72 of adjoined sealed center-filled confectionery piecesas shown in FIG. 8. Segments of strand portion 52 adjoin thecenter-filled pieces. The number of pieces may correspond to the numberof individual center-filled ropes 46 of extrudate 44. Outer portion 50surrounds or otherwise wholly encases inner portion 48 as shown in FIG.8. Each individual sealed center-filled confectionery piece may beidentified by its pillow shape as seen in FIG. 8.

Alternatively, apparatus 10 may include a cutting device (not shown)positioned upstream of forming device 60. The cutting device may cutextrudate 44 along strand portions 52 to form a plurality of discrete orindividual center-filled confectionery ropes prior to passage into theforming device. Consequently, when the plurality of individualcenter-filled ropes are exposed to the crimping and cutting process uponpassage through forming device 60, a plurality of discrete sealedcenter-filled individual confectionery pieces may be formed.

In an embodiment, apparatus 10 may include dispenser (not shown)upstream of forming device 60, the dispenser positioned on either orboth sides of extrudate 44. The dispenser may be used to apply or sprayan adhesion reducer onto some or all of the exterior surface area ofextrudate 44. Nonlimiting examples of suitable adhesion reducers includeoil, food grade oil, talc, calcium carbonate and combinations thereof.In an embodiment, the adhesion reducer may be a food grade oil.Application of an adhesion reducer onto extrudate 44 prior to passagethrough forming device 60 advantageously reduces the occurrence ofadherence of extrudate 44 to the forming device and improves thereleasability of component 66 from first and/or second forming members62, 64.

As is known in the art, adhesion of freshly extruded confectionerymaterial processing equipment and components downstream of the extrudateis a constant problem. In an embodiment, extrudate 44 may be cooledupstream of forming device 60 upon contact to transport device 54 thatmay be a cooling belt. In a further embodiment, fill material 38 may bedelivered through conduits 22 at a reduced temperature. In anembodiment, the temperature of fill material 38 upon exit from orifice26 may be from about 1° C. to about 15° C. or about 3° C. to about 10°C. Provision of cool fill material advantageously cools outer portion 50(i.e., fluid confectionery 36) of each rope 46 from the inside. It isunderstood that a cooling belt, alone or in combination with chilledfill material, may be used to cool extrudate 44 upstream of formingdevice 60.

In an embodiment, apparatus 10 may include a cooling system in operativecommunication with rotating drums 68, 70. The cooling system may be usedto introduce a flow of cool or chilled fluid (i.e., cold water, liquidnitrogen, and the like) into and out of the interior of rotating drums68, 70 in order to cool the circumferential surfaces and correspondinglycool forming members 62, 64. In an embodiment, the forming members 62,64 may have a temperature from about −7° C. to about 25° C., or fromabout 0° C. to about 20° C. Cooled forming members advantageously reducethe occurrence of adhesion between the forming members and extrudate 44and/or confectionery component 66.

In yet a further embodiment, the forming members 62, 64 may includeorifices whereby a jet of air may be blown to assist in the release ofconfectionery component 66 from the forming members.

In an embodiment, apparatus 10 may further include transport device 74for receiving and transporting sealed center-filled confectionerycomponents 66 as shown in FIG. 1. Transport device 74 may transport web72 to a separating device 76 that separates web 72 into a plurality ofdiscrete sealed center-filled individual confectionery products 78. Inan embodiment, separating device 76 may be a breaking drum. Individualproducts 78 may be transported by transport device 80 for furtherprocessing. For example, products 78 may be transported to a coatingdevice to coat the products, products 78 may be transported to a curingdevice for curing, and/or products 78 may be transported to a packagingdevice for packaging.

In an embodiment, a coating may be applied to products 78. Products 78may be coated with coating materials to form a soft shell coating or ahard shell coating as is commonly known in the art. The coating processmay include a repetitive powder charge/syrup charge pan coating processto build, layer by layer, a coating upon each individual product 78.Nonlimiting examples of suitable coating materials include sugars,polyols, or combinations thereof in powder and/or syrup form. In anembodiment, the coating may be a crystalline or a glassy coating. Thesugars or polyols may be, for example, a component of a syrup that issprayed onto products 78 in a pan coating device. Dry charges of thesugar/polyol may be applied between syrup applications. The coating mayalso include a sweetener, a flavorant, a film forming agent, a colorant,a sensation producing ingredient, and combinations thereof. Thesweetener may be sugar, sugar-based, or sugar-free. Non-limitingexamples of suitable sweeteners include, maltitol, sorbitol, erythritol,mannitol, isomalt, lactitol, xylitol and combinations thereof. Highintensity sweeteners may also be utilized in the coating. Nonlimitingexamples of suitable sensation producing ingredients may include acooling agent, a food grade acid, a flavorant, and combinations thereof.Alternatively, web 72 may be coated. Web 72 may be coated with anycoating material and/or coating component as discussed herein, thecoating applied to web 72 may be a pre-coat or a final coat as desired.

FIGS. 9 and 10 depict sealed center-filled confectionery product 78.Center filled confectionery product 78 includes a fill portion 82 thatis surrounded or otherwise encased by outer portion 84. Portions 82 and84 may be any confectionery material as previously discussed herein. Inan embodiment, fill portion 82 may be a liquid such as a flavored and/orsweetened and/or colored syrup and outer portion 84 may be a chewinggum. In an embodiment, apparatus 10 may be used to produce acenter-filled confectionery product as disclosed in commonly-owned,co-pending patent application entitled “Center-Filled Confectionery andMethod,” Attorney Docket No. 0112703-1291, which is concurrently filedherewith and is hereby incorporated by reference in its entirety.

In an embodiment, the forming process (i.e., formation of web 72 withforming members 62, 64) may be coordinated with the filling of theconfectionery ropes with fill material. A controller (not shown) may beoperatively connected to flow regulator 42 and forming device 60. Uponinitial engagement of forming members 62, 64 with extrudate 44 (initialcrimping), the controller may direct flow regulator 42 to initiate flowof fill material 36 into confectionery ropes 46 simultaneously with thecrimping and/or cutting. The flow of fill material may occurintermittently, for about 0.1 seconds to about 3 seconds, for example.Alternatively, the flow of fill material into the ropes may becontinuous. Nonlimiting examples of suitable controllers may include atiming device, a programmable logic control, and the like. In anembodiment, the forming process (i.e., formation of web 72 with formingmembers 62, 64) may be coordinated with the filling of the confectioneryropes with fill material. A controller (not shown) may be operativelyconnected to flow regulator 42 and forming device 60. Upon initialengagement of forming members 62, 64 with extrudate 44 (initialcrimping), the controller may direct flow regulator 42 to initiate flowof fill material 36 into confectionery ropes 46 simultaneously with thecrimping and/or cutting. The flow of fill material may occurintermittently, for about 0.1 seconds to about 3 seconds, for example.Alternatively, the flow of fill material into the ropes may becontinuous. Nonlimiting examples of suitable controllers may include atiming device, a programmable logic control, and the like.

In this context, the controller may direct a pulse pumping of fillmaterial 38 whereby the fill material may be intermittently introducedinto the confectionery ropes simultaneously with the crimping ofextrudate 44 by the forming device 60. This intermittent introduction offill material into the extrudate coordinated with the crimping andcutting action of forming device 60 may advantageously prevent backflowof fill material 36 in extrudate 44 and/or conduits 22. Backflow may beconsidered a flow in a direction opposite of the extrudate flow(extrudate flow shown by direction arrow G). Prevention of backflowbeneficially contributes to the formation and maintenance of ropes 46having a uniform size and diameter along the length thereof and theprovision of a uniform amount of fill material with each rope and alongsubstantially the entire length of the extrudate.

Further advantages of the multiple rope extrusion process provided byapparatus 10 are many. First, provision of straight conduits 22 permitsgreater flow control of the fill material. Straight conduits 22 providea more precise fill and consistent flow rate of fill material into eachrope 46. Moreover, the flow rates between the multiple conduits may becontrolled with a high degree of precision to provide a uniform fillmaterial flow rate between the conduits. In an embodiment, each conduit22 may be operatively connected to a pressure regulator that detects thefluid pressure of the fill material in each rope 46. Any inconsistenciesin pressure between the ropes, resulting from flow blockage for example,may be readily detected and addressed.

Second, the capability to form web 72 of 2, 5, 10, 20, or 30 or moreadjoined sealed center-filled confectionery pieces increases the per-runoutput capacity when compared to conventional single rope processingequipment. This increase in per-run capacity by apparatus 10 permits theflow rate of extrudate 44 to be decreased without a loss in per-runoutput, particularly when compared to production systems based on asingle rope extrusion process. Apparatus 10 thereby provides a slowerextrudate flow rate which enables greater control and precision of 1)filling of fill material 36 into ropes 46, 2) extrusion of fluidconfectionery 38, and 3) the crimping and cutting of extrudate 44 withforming device 60. Improved control of flow and process parameterstranslates into increased production yields—i.e., the reduction orelimination of leakers. Leakers may be considered unacceptable productresulting from a faulty seal of outer portion 50 (fluid confectionery)around inner portion 48 (fill material). Leakers exhibit leakedcenter-fill material on the exterior surfaces of sealed center-filledconfectionery component 66 (either web 72 or pieces 78). Leakers mayresult from improper forming, uneven filling of fill material, andcombinations thereof.

In an embodiment, apparatus 10 may provide an extrudate flow rate fromabout 2 m/mm to 20 m/mm, or about 10 m/min with a product output of 8200individual center-filled confectionery pieces per minute. This stands asa marked improvement over conventional center-filled confectioneryproduction systems that typically operate with an extrudate flow rate ofabout 45 m/min and a product output of about 2600 individualcenter-filled confectionery pieces per minute.

It should be understood that various changes and modifications to thepresently preferred embodiments described herein will be apparent tothose skilled in the art. Such changes and modifications can be madewithout departing from the spirit and scope of the present subjectmatter and without diminishing its intended advantages. It is thereforeintended that such changes and modifications be covered by the appendedclaims.

1. An apparatus for producing a center-filled confectionery productcomprising: an extruder forming an extrudate having a plurality ofcenter-filled confectionery ropes; and a forming device having first andsecond forming members on opposing sides of the extrudate, the formingmembers constructed and arranged so as to cooperatively engage theextrudate to form a sealed center-filled confectionery component.
 2. Theapparatus of claim 1 wherein the plurality of center-filledconfectionery ropes form an integral extrudate.
 3. The apparatus ofclaim 1 wherein the sealed center-filled confectionery component isselected from the group consisting of a web of adjoined sealedconfectionery pieces, a plurality of sealed center-filled confectioneryproducts, and combinations thereof.
 4. The apparatus of claim 3 furthercomprising a separating device for separating the web into a pluralityof individual sealed center-filled confectionery products.
 5. Theapparatus of claim 1 wherein the extrudate further comprises a fillmaterial encased in an outer confectionery material.
 6. The apparatus ofclaim 5 wherein the fill material is a liquid and the outerconfectionery material is a chewing gum.
 7. The apparatus of claim 1further comprising a coating device for coating the sealed center-filledconfectionery component with a coating material.
 8. A method forproducing a center-filled confectionery product comprising: extruding anextrudate comprising a plurality of adjoined center-filled confectioneryropes; and forming the extrudate into a sealed center-filledconfectionery component using a forming device.
 9. The method of claim 8further comprising passing the extrudate between a first forming memberand a second forming member; and cooperatively engaging the formingmembers to form the sealed confectionery component.
 10. The method ofclaim 8 wherein the sealed center-filled confectionery component is aweb of adjoined sealed center-filled confectionery pieces, the methodfurther comprising separating the web into a plurality of individualcenter-filled confectionery products.
 11. The method of claim 8 furthercomprising filling each of the plurality of confectionery ropes with afill material.
 12. The method of claim 11 further comprising cooling thefill material.
 13. The method of claim 11 further comprisingintermittently pumping the fill material into each of the plurality ofconfectionery ropes.
 14. The method of claim 8 further comprisingcoating the sealed center-filled confectionery component with a coatingmaterial.
 15. An apparatus for producing a center-filled extrudatecomprising: a manifold having a passageway; a plurality of annularconduits extending through the passageway, each conduit having adischarge end; and an exit port having an orifice in fluid communicationwith the passageway, the conduit discharge ends disposed in a spacedapart manner within the orifice.
 16. The apparatus of claim 15 whereinthe conduit ends are disposed in a linear arrangement in the orifice.17. The apparatus of claim 15 wherein the orifice further comprises aplurality of wide portions corresponding to the plurality of annularconduits.
 18. The apparatus of claim 17 wherein the orifice furthercomprises a plurality of narrow portions separating the wide portions.19. The apparatus of claim 15 wherein the passageway is adapted toreceive a fluid confectionery and the annular conduits are adapted toreceive a flowable fill material, the fluid confectionery surroundingeach conduit end to form an extrudate comprising a plurality ofcenter-filled confectionery ropes upon exit from the orifice.
 20. Theapparatus of claim 19 wherein each rope has a diameter, the ropediameters having a substantially similar length.
 21. The apparatus ofclaim 19 wherein the number of ropes corresponds to the number ofconduits.
 22. The apparatus of claim 19 wherein the extrudate furthercomprises a strand portion of the fluid confectionery disposed betweenadjacent confectionery ropes, the strand portion adjoining adjacentcenter-filled confectionery ropes.
 23. A method for producing acenter-filled extrudate comprising: extruding a plurality of adjoinedfluid confectionery ropes; and coextruding a fill material into eachconfectionery rope.
 24. The method of claim 23 wherein the confectioneryropes are disposed in a substantially linear arrangement.
 25. The methodof claim 23 further comprising coextruding the fill material from aplurality of spaced apart linearly disposed conduits.
 26. The method ofclaim 23 wherein the extruding and the coextruding occur substantiallysimultaneously.
 27. The method of claim 23 wherein the extruding and thecoextruding occur at a common exit port.
 28. The method of claim 23wherein the extruding further comprises forming with the fluidconfectionery a plurality of annular confectionery ropes.
 29. The methodof claim 23 further comprising concentrically coextruding the fillmaterial within the fluid confectionery ropes.
 30. The method of claim23 further comprising forming the confectionery ropes from a single flowof a fluid confectionery material.
 31. The method of claim 23 furthercomprising intermittently coextruding the fill material into theconfectionery ropes.